High molecular weight polymers having improved crystallization

ABSTRACT

This disclosure relates to a high molecular weight polypropylene-based composition with high nucleation density and short crystallization half time. The composition may contain up to about 2 wt % ethylene.

This application claims priority to U.S. Provisional Application No.62/599,405, filed on Dec. 15, 2017, which is herein incorporated byreference in its entirety.

FIELD OF THE INVENTION

This invention relates generally to high molecular weightpolypropylene-based compositions, more particularly, polypropylene-basedcompositions with improved crystallization behavior.

BACKGROUND

Crystallization kinetics of polymers can affect their materialproperties. A polymer composition with fast crystallization kinetics canthus provide high nucleation densities and small crystals, which canthen provide enhanced material properties (e.g., improved creep,clarity/haze, ductility, and melt strength). Nucleation in polymercompositions is often sped up with nucleating agents or low molecularweight compounds that are blended in during processing.

Therefore, there is an unmet need in the art to produce a polymercomposition in which more nucleation sites can be achieved by tailoringthe polymer composition, without the use of external nucleators. It is afurther object of the current invention to produce a polymer compositionwith fast crystallization kinetics and enhanced material properties.

SUMMARY OF THE INVENTION

One aspect of the invention relates to a high molecular weightpolypropylene-based composition, containing from 0 to about 2% by weightethylene, where the composition has a melt flow rate of about 1.0 g/10min or lower, and where the composition has a nucleation density greaterthan 18,000 nuclei/cm², when nuclei are grown from a melt at 135° C.without the addition of an external nucleating agent, as measured byoptical microscopy.

Another aspect of the invention relates to a high molecular weightpolypropylene-based composition formed by a process including: (1)polymerizing propylene and ethylene with a Ziegler-Natta catalyst systemin a first loop reactor to form a high molecular weightpolypropylene-polyethylene copolymer, (2) polymerizing propylene withthe Ziegler-Natta catalyst system in a second loop reactor to form anaverage molecular weight polypropylene polymer, and (3) extruding thehigh molecular weight polypropylene-based composition, where thecomposition comprises from about 0.10% to about 0.5% by weight ethylene,where the composition has a melt flow rate of about 1.0 g/10 min orlower, and where the composition has a nucleation density greater than18,000 nuclei/cm², when nuclei are grown from a melt at 135° C. withoutthe addition of an external nucleating agent, as measured by opticalmicroscopy.

Another aspect of the invention relates to a high molecular weightpolypropylene-based composition formed by a process including: (1)polymerizing propylene with a Ziegler-Natta catalyst system in a firstloop reactor, to form a high molecular weight polypropylene polymer, (2)polymerizing propylene with the Ziegler-Natta catalyst system in asecond loop reactor, to form an average molecular weight polypropylenepolymer, (3) optionally polymerizing propylene and ethylene with aZiegler-Natta catalyst system in a gas phase reactor, to form an averagemolecular weight polypropylene-polyethylene copolymer, and (4) extrudingthe high molecular weight polypropylene-based composition, where thecomposition comprises from 0 to about 2% by weight ethylene, where thecomposition has a melt flow rate of about 1.0 g/10 min or lower, andwhere the composition has a nucleation density greater than 18,000nuclei/cm², when nuclei are grown from a melt at 135° C. without theaddition of an external nucleating agent, as measured by opticalmicroscopy.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an optical micrograph showing the cylindritic crystals formedin Example 1.

FIG. 2 is an optical micrograph showing the spherulitic crystals formedin Comparative Example 3.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure relates to a high molecular weightpolypropylene-based composition with high nucleation density. Inparticular, the high molecular weight polypropylene-based compositioncomprises from about 0 to about 2 wt % ethylene. It was surprisinglyfound that the nucleation density can be significantly increased bycarefully tailoring the polymer composition. Accordingly, one aspect ofthe invention relates to a high molecular weight polypropylene-basedcomposition, containing from 0 to about 2% by weight ethylene, where thecomposition has a melt flow rate of about 1.0 g/10 min or lower, andwhere the composition has a nucleation density greater than 18,000nuclei/cm², when nuclei are grown from a melt at 135° C. without theaddition of an external nucleating agent, as measured by opticalmicroscopy.

As used herein, a high molecular weight polypropylene-based compositionrefers to a composition comprising a high molecular weight polypropylenehomopolymer or a high molecular weight polypropylene-polyethylenecopolymer. The high molecular weight polypropylene-based compositionalso comprises an average molecular weight polypropylene homopolymer oran average molecular weight polypropylene-polyethylene copolymer. Thepolypropylene-based composition may have a weight average molecularweight (M_(w)) ranging from 500,000 g/mol to 3,000,000 g/mol, or fromabout 800,000 g/mol to about 2,000,000 g/mol. In one embodiment, wherethe high molecular weight polypropylene-based composition comprises ahigh molecular weight polypropylene-polyethylene copolymer, thecomposition also includes an average molecular weight polypropylenehomopolymer. In one embodiment, where the high molecular weightpolypropylene-based composition comprises a high molecular weightpolypropylene homopolymer and an average molecular weight polypropylenehomopolymer, the composition also includes an average molecular weightpolypropylene-polyethylene copolymer. The composition can also includemodifications as well as other components one skilled in the art wouldtypically include in a polypropylene-based composition.

The ethylene content of the high molecular weight polypropylene-basedcomposition ranges from about 0 to about 2 wt % ethylene, including allfraction and integer ranges therebetween. For example, the ethylenecontent can be from about 0.1 wt % to about 1.0 wt %, from about 0.1 wt% to about 0.5 wt %, from about 0.1 wt % to about 0.35 wt %, or about0.3 wt %. In another embodiment, the ethylene content is from about 0.5wt % to about 2 wt %, or about 0.5 wt %. The ethylenes may be present inthe polypropylene-polyethylene copolymer or exist as polyethylenehomopolymer.

Conversely, the high molecular weight polypropylene-based compositioncomprises from about 98-100 wt % propylene content, including allfraction and integer ranges therebetween. For example, the propylenecontent is from about 99.0 wt % to about 99.9 wt %, from about 99.5 wt %to about 99.9 wt %, or about 99.7 wt %. In another embodiment, thepropylene content is from about 98 wt % to about 99.5 wt %, or about99.5 wt %.

In some embodiments, the high molecular weightpolypropylene-polyethylene copolymer has a melt flow rate of less thanabout 0.1 g/10 min, or from about 0.06 g/10 min to about 0.1 g/10 min,when measured with a 2.16 kg melt indexer weight, or a melt flow rate ofless than about 0.3 g/10 min, or from about 0.12 g/10 min to about 0.24g/10 min, when measured with a 5 kg melt indexer weight. In oneembodiment, the high molecular weight polypropylene homopolymer has amelt flow rate of about 0.2 g/10 min or less, or about 0.2 g/10 min,when measured with a 5 kg melt indexer weight. The melt flow rate ismeasured at 230° C. in accordance with ASTM 1238 with 1% antioxidantbutylated hydroxytoluene (BHT) to stabilize powder melt flows.

Overall, the high molecular weight polypropylene-based composition has amelt flow rate of about 1.0 g/10 min or less, or from about 0.1 g/10 minto about 0.4 g/10 min, or from about 0.3 g/10 min to about 0.5 g/10 min,when measured with a 2.16 kg melt indexer weight.

As used herein, the term “nucleation density” refers to the number ofcrystal nuclei in an area of 1 cm². In some embodiments, the crystalnuclei are crystallization seeds that provide nucleation sites for thepolymer chains. The nucleation density can be measured by methods knownto one skilled in the art. For example, an optical microscope, such as abinocular stereoscopic microscope, a brightfield microscope, apolarizing microscope, or a confocal microscope, optionally equippedwith a hot stage, can be used for measuring nucleation density. In oneembodiment, the optical microscope is a confocal microscope equippedwith crossed polarizers and a digital camera.

The high molecular weight polypropylene-based composition has anucleation density greater than 18,000 nuclei/cm², greater than 20,000nuclei/cm², greater than 75,000 nuclei/cm², greater than 100,000nuclei/cm², or greater than 125,000 nuclei/cm², when the nuclei aregrown from a melted composition at 135° C., without the addition of anexternal nucleating agent. The nucleation density is typically not morethan 1,000,000 nuclei/cm². In other embodiments, when the nuclei aregrown from a melted composition at 120° C., the nucleation density isgreater than 100,000 nuclei/cm², greater than 500,000 nuclei/cm², orgreater than 1,000,000 nuclei/cm², with the nucleation density at thattemperature typically not more than 10,000,000 nuclei/cm². The highnucleation density can thus lead to the formation of more crystals.

As used herein, the term “crystallization half time” refers to the timeat which the extent of crystallization has reached about 50%.Crystallization half time is measured from (a) the point in time thesample reaches the desired isothermal temperature (e.g., 120° C. or 135°C.) to (b) the point in time at which the sample reaches the peak heatflow. Alternatively, for fast crystallizing samples, crystallizationhalf time is measured from the point in time at which the sampleexperiences minimum heat flow when cooling from the melt to peakcrystallization heat flow. The crystallization half time can be measuredby methods known to one skilled in the art, for example, by isothermaldifferential scanning calorimetry.

When the nuclei are grown from a melted composition at 135° C., the highmolecular weight polypropylene-based composition typically has acrystallization half time of about 24 minutes or shorter, about 20minutes or shorter, about 15 minutes or shorter, or about 10 minutes orshorter. When the nuclei are grown from a melted composition at 120° C.,the crystallization half time is typically less than about a minute,from about 0.1 minute to about 0.9 minute, from about 0.1 minute toabout 0.7 minute, or from about 0.1 minute to about 0.5 minute.

There are several advantages associated with the high molecular weightpolypropylene-based composition having fast crystallization kineticswithout an external nucleating agent. Firstly, cycle times can bereduced in polymer processing such as extrusion or molding. Secondly,because the step of adding the external nucleating agent is eliminated,there are savings in costs and time. Thirdly, fabricated parts made fromthe high molecular weight polypropylene-based composition may alsosolidify faster, thereby increasing the rate of production.

As understood by one skilled in the art, the term “creep” refers atime-dependent deformation under a continuously applied load. As usedherein, the term “creep strain resistance” refers to the time taken bythe sample to reach a certain deformation threshold when treated with acontinuously applied load at a specific temperature. The creep strainresistance may be measured by standard methods such as ASTM D2990, DINEN ISO 899-1, or DIN 53444.

Another aspect of the invention relates to a method for preparing thehigh molecular weight polypropylene-based composition, comprisingpolymerizing propylene and ethylene, if present, with a Ziegler-Nattacatalyst system to form the high molecular weight polypropylene-basedcomposition. The Ziegler-Natta catalyst system may contain phthalates orbe a non-phthalate system.

Various Ziegler-Natta procatalyst known in the art for polymerizingpropylene and ethylene may be used in the catalyst system, althoughother catalyst systems may be used as well. The Ziegler-Nattaprocatalyst composition typically contains a transition metal compoundand a Group 2 metal compound. The transition metal compound may be asolid complex derived from a transition metal compound, for example,titanium-, zirconium-, chromium- or vanadium-hydrocarbyloxides,hydrocarbyls, halides, or mixtures thereof. In a typical Ziegler-Nattaprocatalyst composition, the transition metal is titanium, the Group 2metal is magnesium, and the halogen is chloride.

The transition metal compound may have the general formulas of TrX_(x)or Tr(OQ)_(g)X_(4-g). Tr is the transition metal, for instance, Tr maybe a Group 4, 5, or 6 metal. In one embodiment, Tr is a Group 4 metal,such as titanium. In another embodiment, Tr is Group 5 metal, such asvanadium. Each Q independently represents a hydrocarbon group, such as aC₁-C₁₀ alkyl group. X represents a halogen atom, such as chloride,bromide, or iodide; x is an integer from 3 to 4; and g is an integerfrom 0 to 4. Exemplary transition metal compounds include, but are notlimited to, titanium trihalides such as TiCl₃, TiBr₃, and TiI₃; titaniumtetrahalides such as TiCl₄, TiBr₄, and TiI₄; alkoxytitanium trihalidessuch as Ti(OCH₃)Cl₃, Ti(OC₂H₅)Cl₃, Ti(OC₄H₉)Cl₃, Ti(OC₂H₅)Br₃, andTi(OC₄H₉)Br₃; dialkoxytitanium dihalides such as Ti(OCH₃)₂ Cl₂,Ti(OC₂H₅)₂Cl₂, Ti(OC₄H₉)₂Cl₂ and Ti(OC₂H₅)₂Br₂; trialkoxytitaniummonohalides such as Ti(OCH₃)₃Cl, Ti(OC₂H₅)₃Cl, Ti(OC₄H₉)₃Cl, andTi(OC₂H₅)₃Br; and tetraalkoxytitaniums such as Ti(OCH₃)₄, Ti(OC₂H₅)₄ andTi(OC₄H₉)₄. Mixtures of two or more such transition metal compounds maybe used as well. The transition metal compound may be used individuallyor in solutions of hydrocarbon compounds or halogenated hydrocarbons.

Suitable Group 2 metal compounds include, but are not limited to,magnesium halides, such as magnesium chloride and magnesium bromide;alkoxymagnesiums, such as ethoxymagnesium, isopropoxymagnesium,butoxymagnesium, and 2-ethylhexoxymagnesium; dialkoxymagnesiums, such asdiethoxymagnesium; alkoxymagnesium halides, such as methoxymagnesiumchloride, ethoxymagnesium chloride, isopropoxy magnesium chloride,butoxy magnesium chloride, and octoxy magnesium chloride; magnesiumoxyhalides; dialkylmagnesiums; aryloxymagnesiums, such asphenoxymagnesium and methylphenoxy magnesium chloride; and carboxylatesof magnesium, such as magnesium laurate and magnesium stearate. Thesemagnesium compounds may be in the liquid or solid state. Typically, theGroup 2 metal compound is magnesium dichloride.

The Ziegler-Natta procatalyst composition may include an internalelectron donor. Suitable internal electron donors include, but are notlimited to, diethers, diesters, cyclic diesters, and succinates, andcombinations thereof. The catalyst system may also include one or moreexternal electron donor compounds.

The Ziegler-Natta procatalyst composition can be activated withorganoaluminum compounds such as trialkylaluminum compounds (e.g.,triethylaluminum, TEAL).

Any kind of polymerization process suitable for preparing a polyolefincan be used. The polymerization can be carried out, for example, in bulkphase using a liquid monomer (e.g., propylene) as a reaction medium, inslurry using an inert liquid (e.g., hydrocarbon) as a diluent, insolution using either monomers or inert hydrocarbons as solvent for thenascent polymer, or in gas phase, operating in one or more fluidized ormechanically agitated bed reactors. The high molecular weightpolypropylene-based composition may be prepared by mixing a synthesizedhigh molecular weight polypropylene homopolymer (or apolypropylene-polyethylene copolymer) with a synthesized averagemolecular weight polypropylene homopolymer, and/or a synthesized averagemolecular weight polypropylene-polyethylene copolymer. The methods tomix polymers are known to one skilled in the art and include solutionblending. In some embodiments, the polymerization process is carried outin industrial loop reactors, such as a Spheripol reactor and aSpherizone reactor, in which the mixing of the high molecular weighthomopolymer/copolymer with the average molecular weighthomopolymer/copolymer occurs concurrently with the synthesis of theaverage molecular weight homopolymer/copolymer. The polymer componentsof the high molecular weight polypropylene-based composition may besynthesized in the loop reactors only or in the loop reactors and thegas phase reactor. In some embodiments where the gas phase reactor isused, the concentration of hydrogen in the gas phase reactor can rangefrom about 50 ppm to about 200 ppm, from about 80 ppm to about 170 ppm,or from about 110 ppm to about 160 ppm. A gas phase ratio (C2/(C2+C3))may range from about 0.01 to about 0.2, or from about 0.02 to 0.11.

The high molecular weight polypropylene-based composition is extruded bymeans known in the art using an extruder or other apparatus. The term“extruder” takes on its broadest meaning and includes any machinesuitable for polyolefin extrusion. For instance, the term includesmachines that can extrude polyolefin in the form of powder or pellets,sheets, fibers, or other desired shapes and/or profiles. The diameter ofthe extruder may range from about 8 mm to more than about 320 mm.Generally, an extruder operates by feeding material through the feedthroat (an opening near the rear of the barrel) which comes into contactwith one or more screws. The rotating screw(s) forces the polyolefinforward into one or more heated barrels (e.g., there may be one screwper barrel). The heated barrels may rotate at a speed of from about 25rpm to about 1,200 rpm. The extrusion temperature may range from 240° C.to 290° C., although temperatures outside this may be suitable,depending on the physical and chemical properties of the composition. Inmany processes, a heating profile can be set for the barrel in whichthree or more independent proportional-integral-derivative controller(PID)-controlled heater zones can gradually increase the temperature ofthe barrel from the rear (where the plastic enters) to the front.Depending on the size of the extrusion equipment, the extrusion rate mayrange from about 3 kg/hr to over 4,500 kg/hr. The extrusion intensitycan be adjusted to low, medium, or high.

The vessel can be, for instance, a single-screw or a twin-screwextruder, or a batch mixer. Further descriptions about extruders andprocesses for extrusion can be found in U.S. Pat. Nos. 4,814,135;4,857,600; 5,076,988; and 5,153,382; all of which are incorporatedherein by reference.

Accordingly, another aspect of the invention relates to a high molecularweight polypropylene-based composition formed by a process including:(1) polymerizing propylene and ethylene with a Ziegler-Natta catalystsystem in a first loop reactor to form a high molecular weightpolypropylene-polyethylene copolymer, (2) polymerizing propylene withthe Ziegler-Natta catalyst system in a second loop reactor to form anaverage molecular weight polypropylene polymer, and (3) extruding thehigh molecular weight polypropylene-based composition. In someembodiments, the process further comprises mixing the high molecularweight polypropylene-polyethylene copolymer and the average molecularweight polypropylene polymer before the extruding step. The compositioncontains from 0 to about 0.5%, from about 0.10% to about 0.5%, or fromabout 0.2% to about 0.35% by weight ethylene. The loop reactor split,which is the ratio of the amount of the high molecular weightpolypropylene-polyethylene copolymer to the amount of the averagemolecular weight polypropylene homopolymer, can range from about 30:70to about 80:20, or from about 50:50 to 70:30. The composition has a meltflow rate of about 1.0 g/10 min or lower. The nucleation density can begreater than 18,000 nuclei/cm², greater than 75,000 nuclei/cm², orgreater than 125,000 nuclei/cm², when nuclei are grown from a melt at135° C. without the addition of an external nucleating agent, asmeasured by optical microscopy. A crystallization half time may be about20 minutes or shorter, or about 10 minutes or shorter, when nuclei aregrown from a melt at 135° C., as measured by isothermal differentialscanning calorimetry. In another embodiment, the crystallization halftime is from about 0.1 minute to 0.5 minute, when nuclei are grown froma melt at 120° C., as measured by isothermal differential scanningcalorimetry.

Another aspect of the invention relates to a high molecular weightpolypropylene-based composition formed by a process including: (1)polymerizing propylene with a Ziegler-Natta catalyst system in a firstloop reactor, to form a high molecular weight polypropylene polymer, (2)polymerizing propylene with the Ziegler-Natta catalyst system in asecond loop reactor, to form an average molecular weight polypropylenepolymer, (3) optionally polymerizing propylene and ethylene with aZiegler-Natta catalyst system in a gas phase reactor, to form an averagemolecular weight polypropylene-polyethylene copolymer, and (4) extrudingthe high molecular weight polypropylene-based composition. In someembodiments, the process further comprises mixing the high molecularweight polypropylene polymer, the average molecular weight polypropylenepolymer, and the average molecular weight polypropylene-polyethylenecopolymer, if present, before the extruding step. The composition caninclude from 0 to about 2%, from 0.1% to about 1.0%, or from 0.2 toabout 0.6% by weight ethylene. The ratio of the amount of the highmolecular weight polypropylene homopolymer to the amount of the averagemolecular weight polypropylene homopolymer can range from about 30:70 toabout 80:20, or from about 50:50 to about 70:30. The melt flow rate canbe about 1.0 g/10 min or lower, or about 0.4 g/10 min or lower. Thenucleation density can be greater than 18,000 nuclei/cm² or 20,000nuclei/cm², when nuclei are grown from a melt at 135° C. without theaddition of an external nucleating agent, as measured by opticalmicroscopy.

In some embodiments, the optional step of polymerizing propylene andethylene with a Ziegler-Natta catalyst system in a gas phase reactor toform an average molecular weight polypropylene-polyethylene copolymer ispresent. In a further embodiment that includes the gas-phase-reactorpolymerization, the composition comprises from about 0.25% to about0.75% by weight ethylene. The amount of average molecular weightpolypropylene-polyethylene copolymer ranges from about 5% to about 40%,or from 10% to 20% by weight, based on a total weight of thecomposition. A crystallization half time is about 15 minutes or shorter,when nuclei are grown from a melt at 135° C., as measured by isothermaldifferential scanning calorimetry. Alternatively, the crystallizationhalf time can be from about 0.1 minute to 0.5 minute, when nuclei aregrown from a melt at 120° C., as measured by isothermal differentialscanning calorimetry.

The polymer compositions of the present invention can include anyconventional plastics additives in any combination. The amount shouldnot be wasteful of the additive. Those skilled in the art ofthermoplastics compounding, with reference to such treatises as PlasticsAdditives Database (2004) from Plastics Design Library(www.elsevier.com), can select from many different types of additivesfor inclusion into the compounds of the present invention.

Non-limiting examples of additives or oligomers are adhesion promoters;antioxidants (e.g., antioxidants containing thioether, phosphite, orphenolic units); flame retardants; biocides (antibacterials, fungicides,and mildewcides); anti-fogging agents; anti-static agents; bonding,blowing and foaming agents; dispersants; fillers (e.g., glass fibers)and extenders; smoke suppressants; expandable char formers; impactmodifiers; initiators; acid scavengers; lubricants; micas; pigments,colorants and dyes; plasticizers; processing aids; other polymers;release agents; silanes, titanates and zirconates; additional slipagents; anti-blocking agents; stabilizers such as hindered amine lightstabilizers; stearates (e.g., calcium stearate); ultraviolet lightabsorbers; viscosity regulators; waxes; antiozonants, organosulfurcompounds, and combinations thereof.

In one embodiment, an additive package includes calcium stearate, athioether antioxidant (e.g., DSTDP), a phenolic antioxidant (e.g., AO1010), and a phosphite antioxidant (e.g., AO 626). In anotherembodiment, the additive package includes an acid scavenger (e.g.,DHT-4V), DSTDP, AO 1010, and AO 626. In yet another embodiment, theadditive package includes DHT-4V, DSTDP, and AO 626.

Antiblock additives are often used together with slip additives and fortheir complementary functions. Antiblock additives reduce adhesion orthe “stickiness” between polymer layers (usually layers of the samepolymer), which is created by blocking forces inherent to many polymers.Whereas slip additives decrease friction caused from moving across thesurface of a polymer, antiblock additives create a microrough surfacethat lessens the adhesion caused by these blocking forces. Antiblockadditives, like slip additives, are commonly used to improve thehandling of a polymer for applications such as packaging. For instance,a non-migratory antiblock additive, such as crosslinked poly(methylmethacrylate) or inorganic silica, can be used.

Antioxidants and flame retardants are commonly used to improve theoxidation resistance and to reduce the flammability of the polymers forunder-the-hood applications; i.e., automotive applications in which thepart or component is located under the hood or otherwise suitable foruse near an engine.

Another aspect of the disclosure relates to an article prepared from thehigh molecular weight polypropylene-based composition. The articleincludes cast films, blown films, oriented films, sheets, and fibers. Insome embodiments, the article may be a fabricated article.

A combination of factors, such as the high nucleation density in thepresently disclosed compositions, and the presence of high molecularweight polymers (i.e., polypropylene homopolymer orpolypropylene-polyethylene copolymer) can lead to an improvedcomposition. Accordingly, the article may be suitable for applicationsthat operate over a broad temperature range for a long duration. Suchapplications include pipe and automotive applications that typically runat high temperatures and pressures. In some embodiments, the article maybe useful for under-the-hood surge tanks. A surge tank helps regulatethe cooling system fluid level in automobiles and provide a place forcoolant expansions or contractions. The entire surge tank can becomposed of the same composition. The size and shape of the surge tankcan vary depending on manufacturer's objectives and material selection.Accordingly, one aspect of the disclosure relates to an under-the-hoodsurge tank prepared from the high molecular weight polypropylene-basedcomposition.

The fabricated article may be formed by a process such as injectionmolding, thermoforming, blow molding and processing equipment withfoaming capability.

Additional aspects, advantages and features of the invention are setforth in this specification, and in part will become apparent to thoseskilled in the art on examination of the following, or may be learned bypractice of the invention. The inventions disclosed in this applicationare not limited to any particular set of or combination of aspects,advantages and features. It is contemplated that various combinations ofthe stated aspects, advantages and features make up the inventionsdisclosed in this application.

Examples

The following examples are given as particular embodiments of theinvention and to demonstrate the practice and advantages thereof. It isto be understood that the examples are given by way of illustration andare not intended to limit the specification or the claims that follow inany manner.

Experimental Method

High molecular weight polymer chains were produced in the first loopreactor of a two loop reactor Spheripol asset with gas phase reactoroptionality. This step was accomplished through low hydrogen addition ofapproximately 40 ppm to the first loop reactor. The high molecularweights of these polymers were reflected in the low melt flow rate(“MFR”) in Table 1.

Compositions based on Material A contained first loop materials thatcontained ethylene, and are listed as Examples 1-3. Example 4, acomposition based on Material B, contains first loop and second loopmaterials composed of polypropylene homopolymers (bimodal) and apolypropylene-polyethylene copolymer composition made in the gas phasereactor.

The melt flow rates (“MFRs”) for the first loop materials for Material Aranged from 0.06 g/10 min to 0.1 g/10 min with a 2.16 kg melt indexerweight and from 0.12 g/10 min to 0.24 g/10 min for a 5 kg melt indexerweight. The MFRs for the first loop materials for Material B had a meltflow of approximately 0.2 g/10 min using a 5 kg melt indexer weight. Forthe MFR measurement, the materials may contain a stabilizer, such as anantioxidant, butylated hydroxytoluene (BHT), at about 1 wt %.

The MFRs for the second loop materials increased as additional hydrogenwas added to the reactor. For Material A, second loop hydrogen was addedat a concentration of roughly 600 ppm. The second loop MFR, the finalMFR, ranged from 0.1 g/10 min to 0.26 g/10 min with a 2.16 kg weight and0.68 g/10 min to 1.0 g/10 min when using a 5 kg weight. The ratio of theamount of the first loop material to the amount of the second loopmaterial was about 60:40. Final ethylene contents for compositions basedon Material A ranged from 0.1 wt % to 0.5 wt %.

For Material B, second loop hydrogen was added at a concentration from3,024 to 4,253 ppm. Compositions based on Material B yielded a MFR up to0.52 g/10 min with a 2.16 kg weight and up to 3 g/10 min when using a 5kg weight. Material B with homopolymer loops also included apolypropylene-polyethylene copolymer made in the gas phase reactor.Final weight percentages ethylene for compositions based on Material Branged from roughly 0.5 to 2. Final MFRs ranged from 0.33 g/10 min to0.47 g/10 min using a 2.16 kg weight and 1.5 g/10 min to 3.1 g/10 minwhen using a 5 kg weight. The ratio of the amount of the first loopmaterial to the amount of the second loop material was about 60:40, andthe amount of the gas phase reactor material was about 10 wt %.

Nucleation Density

The nucleation density, represented as nuclei/cm², was measured onpressed films. Resin pellets were heated to 200° C. between two sheetsof aluminum foil in a Carver platen press at 8 tons for 3 minutes. Filmswere then removed, cut to size, and placed between a glass slide baseand glass coverslip. The assembled slide was then heated to 230° C. for5 minutes to melt the pressed film after which the slide assembly wasplaced in a hot stage at the called out temperature per Table 1. Aconfocal microscope equipped with crossed polarizers and a digitalcamera was then set up to automatically take pictures of the sample asit crystallized. Using a scale bar, nuclei were counted using asoftware, Hirox Advanced Image Analysis Software, bundled with theoptical microscope. The nucleation density was then calculated persquare area of the scale bar used. After which, nucleation density wasconverted to a standard cross-sectional area of 1 cm².

Crystallization Half Times

Crystallization half times were calculated from isothermal DSC (ISO DSC)scans. Samples were pressed between two sheets of aluminum foil in aCarver platen press using 2 metric tons for 30 seconds to initially meltthe sample. After this point, 5½ metric tons of pressure was applied for5 minutes at a press temperature of 200° C. Films were then removed andcut to size for placement in DSC TA TZero aluminum analysis pans. Cutfilms weighed approximately 6.5 mg.

The ISO DSC was run per the following program in a TA Instruments Q200unit:

-   -   Equilibrate at 200.00° C.    -   Isothermal for 5.00 min    -   Ramp (i.e., cool at) 30.00° C./min to the desired isothermal        temperature (120.00° C. or 135° C.)    -   Isothermal up to 120.00 min

Raw ISO DSC data was then taken and analyzed per the following steps:

-   -   Starting time, Time Zero, of the crystallization half time was        calculated to be the time at which the unit reached the desired        isothermal temperature or the minimum Heat Flow (W/g) reached        between equilibrium at 200° C. and the Heat Flow (W/g) of peak        crystallization.    -   Crystallization half time was calculated from Time Zero to time        of peak Heat Flow (W/g).

Shape of the Crystals

The compositions based on Materials A and B formed cylindritic crystals(see FIG. 1) that may develop into typical spherulitic crystalsdepending on the nucleation density and crystal growth rates (i.e.crystal impingement). FIG. 2 shows the typical spherulitic crystals inComparative Example 3.

High Nucleation Densities and Short Crystallization Half Times

Table 1 summarizes the DSC and optical microscopy crystallization data.Applicants achieved high nucleation densities for Examples 1-5. Thesehigh nucleation densities led to significantly reduced crystallizationhalf times for all compositions made in accordance with the invention.

Comparative Example 1 is an impact copolymer in which the ethylene ispresent in the form of propylene-ethylene rubber chains, and has ahomopolymer matrix, which crystallizes from the polymer melt.Comparative Examples 2 and 3 are random propylene-ethylene copolymers.Although Comparative Examples 1-3 exhibited similar nucleationdensities, Comparative Example 1 had a shorter crystallization half timethan Comparative Examples 2 and 3. This result was expected because theincorporation of ethylene in the random copolymer chains of ComparativeExamples 2 and 3 likely slowed down crystal growth.

However, Examples 1-4, which contained ethylene in the polymer chains,unexpectedly exhibited shorter crystallization half times thanComparative Example 1, as well as Comparative Examples 2 and 3. Thisobservation was attributed to the high nucleation density of thecompositions.

High nucleation density was found to be achievable without processing,for example, without applying external shearing forces. Thus, for atleast Example 5, the driving force may be the bimodal molecular weightdistribution in which one mode corresponded to a high molecular weight.

TABLE 1 Melt flow rate, ethylene content, crystallization half time, andnucleation density for presently disclosed polymer compositions andcomparative examples 120° C. 135° C. Total Crystal Nucleation CrystalNucleation Ethylene, Half Time, Density, Half Time, Density, Example MFRMaterial Type wt % min Nuclei/cm² min Nuclei/cm² Example 1 0.1 MaterialA ~0.2 0.22 1,234,957 8.51 378,106 Example 2 0.4 Material A ~0.2 0.25 NM9.49 127,626 Example 3 0.2 Material A ~0.3 0.46 NM 16.93 84,133 Example4 0.3 Material B ~0.5 0.40 NM 14.28 21,952 Example 5 0.3 Homopolymermatrix 0 NM 102,694 NM 19,782 of Material B Comparative 0.3 Impactcopolymer, 0 0.75 NM 27.37 8,107 Example 1 homopolymer matrixComparative 0.6 Mini random 0.5 1.49 26,241 51.86 7,068 Example 2copolymer Comparative 0.2 Mini random 0.4 1.53 32,706 68.90 6,747Example 3 copolymer NM = Not measured

We claim:
 1. A high molecular weight polypropylene-based composition,comprising from 0 to about 2% by weight ethylene; wherein thecomposition has a melt flow rate of about 1.0 g/10 min or lower; andwherein the composition has a nucleation density greater than 18,000nuclei/cm², when nuclei are grown from a melt at 135° C. without theaddition of an external nucleating agent, as measured by opticalmicroscopy.
 2. The composition of claim 1, wherein the compositioncomprises from about 0.1% to about 1.0% by weight ethylene.
 3. Thecomposition of claim 1, wherein the melt flow rate is about 1.0 g/10 minor less.
 4. The composition of claim 1, wherein the nucleation densityis greater than 100,000 nuclei/cm².
 5. The composition of claim 1,wherein the composition has a crystallization half time of about 24minutes or shorter, when nuclei are grown from a melt at 135° C., asmeasured by isothermal differential scanning calorimetry.
 6. Thecomposition of claim 5, wherein the crystallization half time is about15 minutes or shorter.
 7. The composition of claim 1, wherein thecomposition has a crystallization half time ranging from about 0.1minute to about 0.9 minute, when nuclei are grown from a melt at 120°C., as measured by isothermal differential scanning calorimetry.
 8. Thecomposition of claim 7, wherein the composition comprises from about0.1% to about 1.0% by weight ethylene.
 9. A method for preparing thehigh molecular weight polypropylene-based composition of claim 1, themethod comprising: polymerizing propylene and ethylene, if present, witha Ziegler-Natta catalyst system to form the high molecular weightpolypropylene-based composition; and extruding the high molecular weightpolypropylene-based composition.
 10. A high molecular weightpolypropylene-based composition formed by a process comprising:polymerizing propylene and ethylene with a Ziegler-Natta catalyst systemin a first loop reactor to form a high molecular weightpolypropylene-polyethylene copolymer; polymerizing propylene with theZiegler-Natta catalyst system in a second loop reactor to form anaverage molecular weight polypropylene polymer; and extruding the highmolecular weight polypropylene-based composition; wherein thecomposition comprises from about 0.10% to about 0.5% by weight ethylene;wherein the composition has a melt flow rate of about 1.0 g/10 min orlower; and wherein the composition has a nucleation density greater than18,000 nuclei/cm², when nuclei are grown from a melt at 135° C. withoutthe addition of an external nucleating agent, as measured by opticalmicroscopy.
 11. The composition of claim 10, the process furthercomprising mixing the high molecular weight polypropylene-polyethylenecopolymer and the average molecular weight polypropylene polymer beforethe extruding step.
 12. The composition of claim 10, wherein thenucleation density is greater than 75,000 nuclei/cm².
 13. Thecomposition of claim 12, wherein the nucleation density is greater than125,000 nuclei/cm².
 14. The composition of claim 10, wherein thecomposition comprises from about 0.2% to about 0.35% by weight ethylene.15. The composition of claim 14, wherein the composition has acrystallization half time of about 20 minutes or shorter, when thenuclei are grown from a melt at 135° C., as measured by isothermaldifferential scanning calorimetry.
 16. The composition of claim 14,wherein the composition has a crystallization half time of about 10minutes or shorter, when the nuclei are grown from a melt at 135° C., asmeasured by isothermal differential scanning calorimetry.
 17. Thecomposition of claim 14, wherein the composition has a crystallizationhalf time of from about 0.1 minute to 0.5 minute, when the nuclei aregrown from a melt at 120° C., as measured by isothermal differentialscanning calorimetry.
 18. A high molecular weight polypropylene-basedcomposition formed by a process comprising: polymerizing propylene witha Ziegler-Natta catalyst system in a first loop reactor, to form a highmolecular weight polypropylene polymer; polymerizing propylene with theZiegler-Natta catalyst system in a second loop reactor, to form anaverage molecular weight polypropylene polymer; optionally polymerizingpropylene and ethylene with a Ziegler-Natta catalyst system in a gasphase reactor, to form an average molecular weightpolypropylene-polyethylene copolymer; and extruding the high molecularweight polypropylene-based composition; wherein the compositioncomprises from 0 to about 2% by weight ethylene; wherein the compositionhas a melt flow rate of about 1.0 g/10 min or lower; and wherein thecomposition has a nucleation density greater than 18,000 nuclei/cm²,when nuclei are grown from a melt at 135° C. without the addition of anexternal nucleating agent, as measured by optical microscopy.
 19. Thecomposition of claim 18, the process further comprising mixing the highmolecular weight polypropylene polymer, the average molecular weightpolypropylene polymer, and the average molecular weightpolypropylene-polyethylene copolymer, if present, to form the highmolecular weight polypropylene-based composition before the extrudingstep.
 20. The composition of claim 18, wherein the composition comprisesfrom about 0.1% to about 1.0% by weight ethylene.
 21. The composition ofclaim 19, wherein the nucleation density is greater than 20,000nuclei/cm².
 22. The composition of claim 19, wherein the optional stepof polymerizing propylene and ethylene with a Ziegler-Natta catalystsystem in a gas phase reactor to form an average molecular weightpolypropylene-polyethylene copolymer is present.
 23. The composition ofclaim 22, wherein the composition has a crystallization half time ofabout 15 minutes or shorter, when the nuclei are grown from a melt at135° C., as measured by isothermal differential scanning calorimetry.24. The composition of claim 22, wherein the composition has acrystallization half time of from about 0.1 minute to 0.5 minute, whenthe nuclei are grown from a melt at 120° C., as measured by isothermaldifferential scanning calorimetry.
 25. An article prepared from the highmolecular weight polypropylene-based composition of claim
 1. 26. Thearticle of claim 25, wherein the high molecular weightpolypropylene-based composition comprises from about 0.1% to about 1.0%by weight ethylene.
 27. The article of claim 25, wherein the article isa fabricated article.
 28. The article of claim 25, wherein the articleis an under-the-hood surge tank or a pipe.